Compressor technology

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Centrifugal compressor

Barrel

Horizontal Split

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Compressor experience

Installed or on order

Pipeline Centrifugal Multi-Stage Centrifugal

835 687

Total Achievement

1522
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Multi-Stage barrel centrifugal compressors

Over 480 sold since 1957 Vertical split barrel-type design Designed for a broad range of oil and gas applications Four frame sizes Standard impeller selections for performance predictability Maximum working pressure up to 450 bar Suitable for direct-drive by Cooper Rolls/Allison gas turbines, without the need for a gearbox Uses same lube oil as power turbines no requirement for separate oil systems

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Multi-Stage barrel compressors

Full range of hydrocarbon gases

High pressure ratio/head capability

Up to highest operating pressures

Cast/forged steel casings

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Custom casing design within established frame sizes

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Active barrel compressor frame sizes

RBB RCB RDB REB

Maximum Pressure Rating

[BAR] [PSIG]

450 6500 18

230 3200 18

150 2200 18

83 1200 18

Number of Stages

Max. Design Inlet Flow

[m/h] [ACFM] [RPM]

10200 6000
14550

23000 13500
11000

37500 22000
7850

60000 35,300
6500

Max. Running Speed

Standard Impeller Diameters

[mm]/[IN]

351 / 13.75 381 / 15.0 419 / 16.5

521 / 20.5 559 / 22.0

673 / 26.5 711 / 28.0

864 / 34.0

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Multi-Stage barrel compressors

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Multi-Stage centrifugal impeller arrangements

Front-to-Back

Back-to-Back
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Barrel and horizontally split combination

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Pipeline compressors
Over 800 sold since 1955 Seven different models suitable for direct-drive by Cooper Rolls Gas Turbines Tilt-pad journal and thrust bearings Designed to API 617

Dry gas seals

Up to five impellers Uses same lube oil as power turbine, no requirement for separate oil system Choice of axial inlet or opposed-flange casings

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Pipeline compressor types

Conventional Horizontally opposed nozzles/side inlet Beam-style (and overhung) rotor designs Wide pressure ratio/head flexibility - up to five stages High aerodynamic efficiencies Fixed casing design per frame size Fixed pressure ratings up to 155 bar Axial inlet Highest aerodynamic efficiencies: Near 90% isentropic Limited to single-stage designs Overhung rotor design Pressures up to 125 bar Fixed casing design per frame size

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Active pipeline booster frame sizes

Nozzle Arrangement Inlet Bearing Arrangement

RC14 Side Inlet OHung OHung & Beam 1-3 [BAR] [PSIG] 105 105/125 1500 1500/1800 11300 103000 6640 14500 495/457 19.5/18

RF20 Side Inlet

RF30 Side Inlet OHung & Beam

RF36 Side Inlet OHung & Beam 1-4 95/155 1380/2250

RF42 Side Inlet OHung & Beam 1-5 105 1500

RFA24 Axial Inlet OHung

RFA36 Axial

Beam

Number of Stages Max. Casing Rating

1-4 105 1500

1-4 100 1440

1 103 1500

Max. Design Inlet Flow [m/h] [ACFM] Max. Operating Speed [RPM] Max. Impeller Diameter [mm] [INCH]

22000 13000 14500 660/533 26/21

52300 30800 7000 1230/1050 48.5/41.5

77000 45400 7000 1230/1050 48.5/41.5

107000 62800 7000 1230/1050 48.5/41.5

43000 25300 14500 710 28.0 60500 7000 1230 48.5

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Pipeline centrifugal compressors

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Pipeliner cross section

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Typical RFA 36 pipeline booster performance map

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Fluid film tilting pad bearings

Rotor supported by a hydrodynamic pressurized oil film generated between the rotor & white metal

lined bearing pads

Well established & accepted technology Compact cartridge design High stiffness & damping capabilities High load capacities High reserve capacities - Resistant to upsets Requires complex oil supply & control system
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Shaft sealing technologies

Bushing Seals: Principle: Injection of regulated high pressure oil between two adjacent cylindrical white metal / aluminum lined rings at each end of compressor Single breakdown seals up to ~ 140 bar Double breakdown seals for higher pressures

Configs:

Dry Gas Seals:

Principle:

Use cleaned & dried process gas at discharge pressure bleeding across highly polished & profiled radial faces separated by very small clearances Tandem seal with second stage as safety back-up Triple seal required above 140 bar

Configs:

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Dry gas seals

Advantages Oil Free Simple, low maintenance control system Limitations Tandem seals limited to 140 bar No rotor damping Limited axial travel

Requires clean & dry sealing gas

Sensitive to lube oil migration - Requires buffer air and barrier seal Complex design No on-site maintenance Requires high installation skill Sticking problems High cartridge cost
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Tandem dry gas face seal

Primary Rings Carbon Faces (Stationary) (Rotating)

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Active magnetic bearings

Magnetic Rotor supported by electromagnetic fields Requires significant air cooling for power outages

Requires auxiliary bearings

Promising technology - Fairly new to large industrial turbo machinery (1988)

Large bearing dimensions

Reduced stiffness & damping capabilities Limited load capacities Limited reserve capacities - Easy to upset Requires complex digital control system Requires careful system tuning
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Magnetic and auxiliary journal bearings

Magnetic and auxiliary journal bearings

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Magnetic and auxiliary journal bearings

009665/09 PPT

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RF2BB30 with magnetic bearings

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Inlet guide vanes

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Inlet guide vane performance

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Compressor running tests

Aerodynamic performance
Type of test Purpose

Modified ASME PTC 10 Class 3: Typical

Full ASME PTC 10 Class 3:

Performance Validation on Pipeline Compressors

Performance Validation - All Compressors

Full ASME PTC 10 Class 1: High Compressors

Performance Validation on Pressure Multistage Confirmation of Rotor Stability Absence of Rotating Stall
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Compressor running tests

Mechanical and rotordynamic performance
Type of test Purpose

Standard API-617 Mechanical:

Confirmation of Mechanical Performance - All Compressors Confirmation of Mechanical Performance - High Pressure Multistage Compressors Confirmation of Rotor Stability Absence of Rotating Stall Same as Above
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Full Density & Speed String:

Full ASME PTC 10 Class 1 String:

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Major compressor development programs

Continuous Stage Efficiency Improvement

Allison Compressor Frame Size Development

Cycle Time Cost Reduction

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Compressor stage efficiency improvement

Development Plan

Select / develop new advanced aerodynamic design software Calibrate the new software with development testing Perform parametric studies necessary to define basic stage geometry

Redesign both barrel and pipeline compressor families as

necessary to upgrade performance Populate each family with standard designs
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Compressors for the CR-501 and CR-601

RCBB-14 Flange Size, in. No. Stages Max. Power Design Speed Max. Design Point Flow (ACFM) (m3/h) Optimum Effcy Typical Driver 501-KC7 RFBB-20 14 1-3 7500 9000-13800 RFA-24 20 1-4 15000 9000-11500 RBB 24 1 18000 9000-13800 6-12 1-8 35000 9000-13800

6640 11300 83-85% 501-KC5 601-KC11

13000 22000 83-85% 601-KC9 501-KC7 601-KC9 601-KC11 1500 105

25300 43000 86-88% 501-KC5 501-KC7 601-KC9 601-KC11 1500 105

6000 10200 78-80% 501-KC5

MWP, psig bar

1500 105

4000 275

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Cycle time and cost reduction

Lead time Objective: Start 1-Jan-98 Target 100% 65%

Measures:
Improved Engineering Tools Rationalization of Supplier Base Expansion of Manufacturing Cells concept to all

components
Improved Fabrication & Packaging Techniques

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Summary
50 years of experience in centrifugal compressors Concentration on oil and gas applications since 1972 Broad model range for all natural gas applications High, field-proven efficiency and dependability Single to multiple unit trains, gas turbine or motor driven (including variable speed motors up to 30MW) Early introduction and leadership in the use of advanced shaft sealing and bearing technology, eg - more than 200 compressors with dry gas seals since 1985

- 24 pipeline compressors with active magnetic bearings

- 5 to 25MW, 8500 to 5000 rpm State-of-the-art fabrication, testing and packaging techniques Compliance with all major international technical standards
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